CN103180966A - Improved photovoltaic cell assembly - Google Patents

Improved photovoltaic cell assembly Download PDF

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CN103180966A
CN103180966A CN2011800512254A CN201180051225A CN103180966A CN 103180966 A CN103180966 A CN 103180966A CN 2011800512254 A CN2011800512254 A CN 2011800512254A CN 201180051225 A CN201180051225 A CN 201180051225A CN 103180966 A CN103180966 A CN 103180966A
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conducting element
conductive
battery
photovoltaic cell
cell
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CN103180966B (en
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M·德格鲁特
M·G·朗格洛伊斯
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Dow Global Technologies LLC
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
    • H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
    • H02S20/25—Roof tile elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/36—Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Photovoltaic Devices (AREA)
  • Manufacturing & Machinery (AREA)

Abstract

The present invention is premised upon an improved photovoltaic cell assembly that include at least plurality of photovoltaic cells with a photoactive portion with a top surface, a top collection structure on the top surface and an opposing conductive substrate layer on a side of the photoactive portion opposite the top surface. Also including a first conductive element with a first surface and wherein the first conductive element is bent at least once and wherein the first surface is in contact with the top collection structure and/or the top surface of a first photovoltaic ceil and the opposing conductive substrate layer of an adjacent second photovoltaic cell; further wherein at least a portion of the first surface is held in contact to the ceils by an adhesive.

Description

Improved photovoltaic cell component
Priority request
The application requires the applying date rights and interests of U.S. Provisional Application number 61/380,457 (submission on September 7th, 2010), and the content of described U.S. Provisional Application is incorporated into it in full by reference at this.
Invention field
The present invention relates to improved photovoltaic (PV) battery component, relate more specifically to use conducting element folding or bending that the bottom conductive substrate is connected with the top conductive structure of adjacent cell and with the improved photovoltaic cell component of a plurality of cell interconnects.
Background technology
Thin-film solar cells provides several advantages, particularly when being used for building integrated photovoltaic application, when namely for example being integrated into device in building structure as roof tiles or exterior wall cladding material.A kind of such advantage is that these compositions have for the high cross-sectional area that absorbs incident light.That is to say, very thin photovoltaic layer can absorb the incident light of relative high percent and convert it into electric power.For example, in many thin-film solar cells devices, photovoltaic layer can have approximately 1 μ m to the about thickness of 4 μ m scopes.The device that these thin layers have allowed to integrate these layers is flexible.
The usual manner of photovoltaic cell assembling is so-called string-contact pin (string﹠amp; Tab) method wherein uses flat wire (bus) bar of tin or solder-coated that solar cell is connected to each other, and by the welding and/or other adhesive materials for example conductive epoxy resin it is bondd.Conductor strip is bonded to the busbar position on the conductive grids that puts on battery surface usually.The cross section that it is believed that wire may be restricted, because thicker electric wire much higher hard, and the conduction of Bao Hekuan is blocked too much light.Final result is the remarkable reduction that the amount of interconnection resistance loss and the battery active surface area that stopped by band may cause the performance of photovoltaic cell component (and therefore PV device).String and contact pin method are particularly suitable for wherein, and photovoltaic cell is in the photovoltaic application of rigidity.The method may be difficult to use in thin-film solar cells, because the battery that obtains series connection string may be frangible, and is easy to occur the forfeiture that contacts between PV band and solar cell.In addition, the outward appearance of the large total line on the PV apparatus surface may be attractive in appearance not for client.
A kind of mode with thin film solar cell interconnect is so-called " lapping (shingling) " method, and the bottom conductive surface of one of them solar cell contacts with the top surface of adjacent cell.Equally, this method can cause being easy to lose the solar cell interconnect of contact between device.
The document relevant with this technology comprises following patent documentation: U.S.6,936,761, U.S.7,022,910, U.S.7,432,438, U.S. discloses 2007/0251570,2009/00025788 and 2009/0255565, and all patent documentations are incorporated into for all purposes by reference at this.
Summary of the invention
The present invention relates to solve at least one or the improved photovoltaic cell component of a plurality of problems described in top paragraph.
It is believed that the present invention's potential advantage compared with prior art is, photovoltaic cell component of the present invention is not so that the horizontal plane of solar cell needs the mode that the coplanar electricity of keeping between photovoltaic cell basically connects to construct and configure.This is also providing the extra degree of freedom aspect the flexibility of module outside the flexibility that is provided by flexible solar battery.Extra flexibility is by preferably providing around the longitudinal axis (i.e. the axle parallel with the longest dimension) folding (or bending) conductive interconnection element at least one times.Imagine described folding (or a plurality of folding) can be or not the center of conductive interconnection element and/or along the position of its longitudinal axis, as long as it is folding at least one times.Photovoltaic cell component described herein does not hinder the large total line that light enters battery yet.Lacking total line also makes the PV device compare more attractive aesthetically with using string with the conventional products that the contact pin mode prepares.In addition, make in this way and can reduce by cancelling the large silver-colored busbar that often is applied to use the photovoltaic cell component that string and contact pin mode prepare the consumption of silver-colored conductive ink when applying grid.Imagination can be encapsulated in battery strings in polymer multilayer structure (laminate) after applying conducting element.Another advantage of imagination is with adhesive or is welded to connect and compares and can have the tolerance of raising to thermal cycle and humid heat treatment, described adhesive or be welded to connect may be easy to degraded under the ambient pressure of these types.
Therefore, according to an aspect of the present invention, imagined a kind of photovoltaic cell component, it comprises a plurality of at least photovoltaic cells, and described battery comprises the opposite conductive basal layer on the side opposite with described top surface of the photolytic activity part, the top current collecting on described top surface and the described photolytic activity part that have at least top surface; The first conducting element with first surface, wherein said the first conducting element bending is at least one times; The opposite conductive basal layer of the described top current collecting of described first surface and the first photovoltaic cell and/or described top surface and adjacent the second photovoltaic cell contacts; In addition, at least a portion of wherein said first surface keeps in touch by adhesive and described battery.
The present invention can further characterize by one of feature described herein or its any combination, for example described a plurality of photovoltaic cell also respectively comprises leading edge and trailing edge, wherein said conducting element and described the first photovoltaic cell contact at described trailing edge place, and the opposite conductive basal layer of described conducting element and described adjacent the second photovoltaic cell is in the place's contact of described leading edge; The leading edge of described adjacent the second photovoltaic cell and the trailing edge of described the first photovoltaic cell are overlapping; Described top current collecting comprises a series of isolated electric conducting material traces, and it is compared with described top surface has lower sheet resistance; The top current collecting comprises at least one bus; At least a portion of described battery form peripheral edge portions comprises the non-conductive layer part; Described non-conductive layer partly comprises by the liquid dielectric of UV hardening with radiation or non-conductive band; Described conducting element is the conductivity adhesive tape; Described conducting element is the foil belt with embossed surface, and at least 10% surface area of wherein said embossed surface directly contacts with described battery; Described adhesive is conductive adhesive; Or described adhesive is non-conductive adhesive; Described at least one angle α that is bent to form is between 0 ° to 90 °; The overlap length of described conducting element and described conductive basal layer is 2.0mm at least; The area at least about 10% of the lap of described conducting element and described bus is overlapping; Described conducting element comprises a plurality of folding.
Therefore, according to a further aspect in the invention, imagined a kind of method of making photovoltaic module, described method comprises the steps: that (a) provides at least two solar cells, described solar cell comprises photolytic activity part, top current collecting and the bottom conductive substrate with top surface, and wherein said battery comprises leading edge and trailing edge in addition; (b) provide at least one conducting element, it respectively has first surface; (c) provide at least one end bar; (d) place the first battery so that with described a plurality of solar cells in the basal surface of the close described conductive substrates of the described leading edge of the first battery contact the first end bar; (e) use conductive component that the first end bar is connected with described the first battery; (f) the first conducting element is folding at least one times around axle; (g) described folding conducting element be applied to described the first battery near the top of described trailing edge and accurately place, so that top surface and/or the described top current collecting of the described solar cell of described conducting element contact; And (h) the second battery is placed on the described folding conducting element that is applied on described the first solar cell, so that the described folding conducting element of the basal surface of the conductive substrates of described the second solar cell contact, thereby produce the string with the first battery and end cell; (i) randomly that other conducting element is folding at least one times around axle, described other folding conducting element is applied to described end cell near the top of described trailing edge and accurately places, so that top surface and/or the described top current collecting of the described solar cell of described conducting element contact; And other battery is placed on the described folding conducting element that is applied on described end solar cell, so that the described folding conducting element of the basal surface of the conductive substrates of described other solar cell contact, have the string of the first battery and at least one intermediate cell and end cell with formation, wherein last end cell becomes intermediate cell; (j) repeating step (i) randomly; (k) place the second end bar, so that its top surface with last end solar cell contacts on bus, described bus is the part at the current collecting edge of described end solar cell; (l) use conductive component that described the second end bar is connected with described last battery.
Should be realized that, aspect above-mentioned and example are nonrestrictive, because as shown in herein and describe, also have in the present invention other aspects and example.
Description of drawings
Fig. 1 is the top perspective of one exemplary embodiment of the present invention.
Figure 1A is the vertical view of the following battery of Fig. 1, comprises exemplary bus.
Fig. 2 is the exploded view of embodiment shown in Fig. 1.
Fig. 3 is the more detailed end view of embodiment shown in Fig. 2.
Fig. 4 is the more detailed end view of embodiment shown in Fig. 1.
Fig. 5 is the more detailed end view of Fig. 4, shows the layer of example.
Fig. 6 is the top perspective comprising the PV device of 4 cell photovoltaic battery components.
Fig. 7 A-7D is the end view of exemplary bending conducting element.
Fig. 7 E-F is the top perspective of two conducting elements, and the Length Ratio width of one of them element is long, and the width of an element is longer than length.
Fig. 8 A-8B is end view, shows the example of the battery on Different Plane.
Fig. 9 is the top perspective of the illustrative example of a trace with end bar and alternate configuration of the present invention.
Detailed description of the preferred embodiment
The present invention relates to the improved photovoltaic cell component 10 as shown in Fig. 1-5, and can usually be described as bringing into play a plurality of parts of the function that electric energy is provided and the assembly of component set when being subject to solar irradiation (for example, daylight).In one embodiment, improved photovoltaic cell component 10 can be incorporated in larger photovoltaic devices, for example in the solar energy house top board 100 shown in Fig. 6.
Special concern point of the present disclosure and principal focal point are a kind of improved photovoltaic cell components 10, and it comprises a plurality of at least photovoltaic cells 20 and conducting element 60 and optional the first and second encapsulating material layer 40,50.Folded or the bending of conducting element 60 and is connected the conductive substrates 22 of a battery at least one times with the top conductive structure 26 and/or 28 of adjacent cell.In a preferred embodiment, conducting element 60 along its longest dimension (namely along its length L C) fold at least one times.Yet, in some embodiments, surpassing once or concertina fold if for example fold, described folding can be along different dimensions (as shown in Fig. 7 A-F).In general, a plurality of photovoltaic cells can be made of a plurality of layers that adjoin.These layers can be further limited (for example from the bottom up) for comprising at least: conductive basal layer 22, photoactive layer 24 and top current collecting 28.Further preferably comprise non-conductive layer part 30 along a part of peripheral edge of battery at least, for example as shown in FIG. 5.In addition, when assembly 10 was constructed such that proper conducting element 60 folded at least a time, both contacted the top current collecting 28 of the first surface of conducting element 60 and the first photovoltaic cell and the opposite conductive basal layer of adjacent photovoltaic cell 22.
Has beat all importance one or more problems that relation between imagination parts and component set (for example geometric properties and material character) is at least discussed in background parts above solving.In paragraph below, more detailed and disclose particularly all parts and component set and relation thereof.
Conductive basal layer 22
Aspect the electric energy that conductive basal layer 22 is partly produced by photolytic activity in conduction, performance is similar to the function of top conductive layer 24.Conductive basal layer 22 can be rigidity or flexible, but it is desirable to flexible, the photovoltaic devices that particularly obtains therein can with embodiment that non-planar surface is combined with in.Conductive basal layer can be single integral layer, perhaps can form from the layer that one or more materials by wide region (comprising metal, metal alloy, intermetallic composition and/or their combination) form.For the application that wherein needs flexible base layer, layer 22 is generally tinsel.The example comprises and comprises Cu, Al, Ti, Mo or stainless tinsel.In typical case, this conductive basal layer is formed by stainless steel, and forms photolytic activity part 24 above basalis, although also imagine other configurations and they must not affect the concept of the cell interconnect that proposes herein.In exemplary, stainless steel is preferred.
Conductive basal layer 22 can apply the electric conducting material of wide region on one or two side, comprise one or more in Cu, Mo, Ag, Al, Cr, Ni, Ti, Ta, Nb, W and/or their combination.Can use the electrically conductive composition that is mixed with Mo in exemplary.The back contact 122 that next-door neighbour's photoactive layer forms on conductive basal layer helps photoactive layer 24 and support are separated to minimize the migration of support composition in the photoactive layer.For example, back contact 22 Fe and the Ni composition that can help to block the stainless steel support moves in photoactive layer 24.Also can the protecting group bottom avoid the degraded that may cause in photoactive layer 24 forming processes at the conductive metal layer that forms on one or two side of conductive basal layer 22; if for example use S or Se in the formation of photoactive region 24, by being provided, the protection for S or Se come the protecting group bottom to avoid degraded.
Photolytic activity part 24
The photoactive layer of photovoltaic cell 20 or part 24 contain the material that luminous energy is transformed into electric energy.Can use any known material that this function is provided, comprise amorphous silicon, CdTe, GaAs, DSSC (so-called Graetzel battery), organic/polymer solar battery, or sunlight is transformed into any other material of electricity by photoelectric effect.Yet photovoltaic cell is preferably the battery based on the IB-IIIA chalcogenide, for example IB-IIIA selenides, IB-IIIA sulfide or IB-IIIA selenides sulfide (be that absorbed layer is the IB-IIIA chalcogenide, be preferably the copper chalcogenide).Example comprises Cu-In selenide, Copper Indium Gallium Selenide compound, copper gallium selenides, copper indium sulfide, copper indium gallium sulphur compound, copper gallium selenides, copper indium sulfide selenides, copper gallium sulfide selenides and copper indium gallium sulphur compound selenides (it all is called CIGS in this article) more specifically.They also can use chemical formula CuIn (1-x)Ga xSe (2-y) S yThe expression, wherein x be 0 to 1 and y be 0 to 2.Cu-In selenide and Copper Indium Gallium Selenide compound are preferred.Except absorbed layer, described part 24 can also comprise a plurality of layers, such as one or more for based in emission (buffering) layer of the battery of CIGS, conductive layer (such as transparency conducting layer) etc. known in the art, also consider in this article these layers.These batteries can be flexible or rigidity, and can have various shape and size, but fragility normally, and be easy to occur environment degradable.In preferred embodiments, photovoltaic cell 20 can be bent and significantly do not break and/or there is no the battery of remarkable loss function.During exemplary photovoltaic cell is instructed and is described in a plurality of United States Patent (USP)s and disclosed, comprise US3767471, US4465575, US20050011550 A1, EP841706 A2, US20070256734 A1, EP1032051A2, JP2216874, JP2143468 and JP10189924A, it is incorporated into for all purposes by reference at this.
In exemplary, photoactive layer 24 also can further be formed by any amount of layer structure, for example: back contact 122 (being generally Mo), absorbed layer 124 (being generally CuInGaSe (S)), resilient coating 126 (being generally CdS), window layer 128 (being generally ZnO) and transparency conducting layer 130 (being generally tin indium oxide (ITO) or aluminium zinc oxide (AZO)).The battery 20 that it is believed that this configuration is commonly called " CIGS solar cell ", referring to Fig. 5 A-A.
Imagination photovoltaic cell 20 can be formed by other known solar cells technology.Their example comprises the solar battery apparatus based on amorphous silicon or cadmium telluride.In addition, the parts in photovoltaic cell 20 as above can replace with substitution material.For example, resilient coating 126 can use sulfide, selenides or the oxide of Cd, Zn, In, Sn and combination thereof to replace; Can comprise the optional window layer that the transparent impedance oxide by for example Zn, Cd, In, Sn consists of between buffering area 126 and transparency conducting layer 130.Under preferable case, the window layer is native oxide zinc.
Transparency conducting layer 130 can be set to the top layer of photoactive layer 24.Can mix transparent conductive oxide or its combination widely in transparency conducting layer.In typical embodiment, transparency conducting layer 130 is transparent conductive oxide (TCO), and its representative example comprises the zinc oxide (AZO), zinc oxide of tin oxide, tin oxide, indium oxide, tin indium oxide (ITO), the aluminium doping of fluorine doping, their combination etc.In an illustrative embodiment, transparency conducting layer is tin indium oxide.Transparency conducting layer can form easily by sputter or other suitable deposition techniques.
Imagination may not need independently transparency conducting layer 130 in some photovoltaic cell 20.For example, GaAs type battery does not need transparent conductive body usually, because the GaAs layer can conduct electricity fully.For purposes of the present invention, the layer that is right after below current collecting 28 should be regarded as the top surface 26 of battery 20.
These substitute the concept that it is known to the person skilled in the art that and do not affect cell interconnect in this paper.
Top current collecting 28
The function of top current collecting 28 is collect the electric energy that is produced by photolytic activity part 22 and it is focused in conductive path.Current collecting 28 can be deposited over photoactive layer 24 tops (for example on top surface 26) with the effective thin layer resistance of the top surface layer (for example tco layer 130) of reduction battery.Current collecting 28 can comprise opaque material on optics usually, and can be used as a series of substantially parallel conductive traces 27 and apply (although also it is contemplated that other structures, and they must not affect the concept of cell interconnect in this paper, as shown in Figure 9), wherein the interval between trace makes grid occupy the area of coverage relatively little on the surface.A kind of exemplary other current collectings 28 structures are presented in Figure 1A, wherein structure 28 comprise totally perpendicular to shown in other conductive traces 27 bus 29 of extending.In a kind of preferred implementation, near bus 29 can be positioned at the peripheral edge of battery 20 in trailing edge 34 places (for example approximately 10.0mm within).More preferably in situation, it is oriented to and the direct adjacency of non-conductive layer part 30.
For example, in certain embodiments, current collecting accounts for and light active material is exposed to catch approximately 5% or lower of relevant total surface area to light in incident light, and even approximately 2% or lower, or even approximately 1% or lower.Current collecting 28 preferably includes conducting metal for example Ag, Al, Cu, Cr, Ni, Ti, Ta and/or its combination.In an illustrative embodiment, grid has the double-layer structural that comprises nickel and silver.Current collecting can be formed by multiple technologies, comprises silk screen printing, ink jet printing, plating and the metallization that the use physical gas phase deposition technology for example evaporates or sputter is undertaken by shadowmask.
Non-conductive layer part 30
Non-conductive layer part 30 plays insulator or dielectric effect, and it is with the edge electric isolation of conducting element 60 with solar cell.It is envisaged that, the existence of non-conductive layer part reduced the solar battery edge place may by with the generation that contacts caused electrical short of conducting element 60.One of the leading edge of each single solar cell or trailing edge 32,34 or both places in solar module, insulator can be applied on solar cell or conducting element 60.Insulator can be crossed over along the edge of device solar battery edge at conducting element position forms as discrete zone, and perhaps it can apply as single layer so that it can be included between battery and conducting element 60 discrete layer along the whole length at battery 20 edges or major part.Insulator can be and to solidify or crosslinked type with the synthetic polymer that forms solid material as liquid deposition.Solidify or crosslinked can the realization by for example applying heat energy or ultraviolet (UV) energy.For the composition of UV-curable, expectation be that solidification process can be completed within the short time period, for example be shorter than 10 seconds, more particularly can be shorter than approximately 3 seconds.Many photo curable polymer need to be in the 200-400nm scope 300mJ/cm at least 2More be typically approximately 500-1200mJ/cm 2The UV energy.Exemplary embodiment comprises the composition based on acrylate and epoxy resin.Alternatively, non-conductive layer part 30 can be used as solid material and applies, for example the form to be with.The substitute that is fit to can comprise fluorocarbon polymer for example ethylene-tetrafluoroethylene copolymer (ETFE), can be coated in curable insulating polymer on battery or interconnection material and maybe can put on Inorganic Dielectric Material on solar cell or interconnection material.Imagining it also can replace as encapsulating material layer 40,50 material, for example polyethylene film.In preferred embodiments, non-conductive layer part 30 is the liquid dielectric-epoxy resin combinations by the UV radiation curing.In an illustrative embodiment, described part 30 is polyimides bands.A kind of so commercially available band is by Dupont
Figure BPA00001702376400101
The Kapton that provides
Figure BPA00001702376400102
Band.In general, non-conductive layer part 30 can show greater than about 2 dielectric constant, and even can be greater than approximately 4.Exemplary electrical insulating material has greater than about 4.8 dielectric constant with greater than approximately 3 * 10 14The specific insulation of Ω-cm.
Conducting element 60
Conducting element 60 plays the effect of the electric bridge between photovoltaic cell 20.Imagined in the present invention between the conductive basal layer 22 of top (for example current collecting 28 and/or top surface 26) at a battery and contiguous cells and formed electric bridge.Ideally, this element has relatively low resistivity (preferably lower than about 1.0 Ω/m, more preferably less than about 0.20 Ω/m, most preferably lower than 0.05 Ω/m).They can or carry out any similar structures of above-mentioned bridging functionality for the form of conductive foil or conductive tape.Illustrative conducting element metal forming comprises Cu or Al, and can be coated with Ag, Sn or Ni.According to a kind of execution mode, can apply adhesive so that the means that paillon foil are attached to top surface and the basal surface of solar cell to be provided to metal forming.It is envisaged that, it can be conductivity or dielectric adhesive that the metal forming adhesive tape can comprise.The example of commercially available metal forming adhesive tape comprise by
Figure BPA00001702376400103
The EMI protective tapes that provides (shielding tape).In the exemplary embodiment, the metal forming adhesive tape comprises non-conductive acrylic acid adhesive.
In a preferred embodiment, conducting element 60 applies at the current collecting 28 of leading edge 32 location and top surface 26 contacted zone along the trailing edge 34 of the first photovoltaic cell and photovoltaic cell.Imagination conducting element 60 is crossed over the length (L of the trailing edge 34 of single battery C) can be 50% changing in up to the scope that strides across whole length of being low to moderate battery length, as shown in Figure 2.The length of conducting element 60 is generally the 50-100% of trailing edge length, is preferably the 75-100% of trailing edge 34 length, even more preferably the 85-95% of trailing edge 34 length.Under preferable case, at least a portion of the bus 29 of conducting element contact current collecting 28.In the exemplary embodiment, bus 29 and conducting element 60 have approximately uniform length.
It is envisaged that the width (W of conducting element 60 c) should be to provide enough to contact to satisfy the size that resistivity requires (for example less than about 1.0 Ω, be more preferably less than approximately 0.2 Ω, even be more preferably less than approximately 0.05 Ω) between element 60 and conductive basal layer 22 and current collecting 28 and top surface 26.In a kind of preferred implementation, at least for conductive basal layer 22, lap " C A" be approximately 2.0mm to 50.0mm, more preferably from about 5.0mm to 50.0mm, 10.0mm to 25.0mm most preferably from about.In another kind of preferred implementation, at least for current collecting 28 and top surface 26, lap " C A" be approximately 2.0mm to 20.0mm, more preferably from about 2.0mm to 15.0mm, 2.0mm to 10.0mm most preferably from about.In another kind of preferred implementation again, at least for the current collecting 28 that has bus 29, lap " C A" can cover bus 29 areas at least about 10%, more preferably from about 50%, most preferably from about 100%.
The outer surface (first surface) 66 of having imagined conducting element comprises adhesive, described adhesive is attached on battery 20 conducting element 60, although adhesive also can be positioned on battery to be positioned in addition the adhesive on battery the adhesive on replacement element 60 or the adhesive on element 60.When conducting element is metal forming, can apply conductive adhesive composition for example conductive epoxy resin or scolder, metal forming is adhered to top surface and the basal surface of solar cell.In a preferred embodiment, conductive adhesive comprises epoxy resin (being generally the epoxy resin based on bis-phenol), curing agent and conducting metal particles at least.Conducting metal particles is preferably silver or copper particle, and preferably accounts at least 30%, more preferably at least 50% of conductive adhesive weight composition.When conducting element was the conducting metal foil belt, adhesive can be conductivity or dielectric adhesive.For the metal forming adhesive tape with conductive adhesive, adhesive segment can comprise organic (non-conductive) adhesive components and conductive particle.In the exemplary embodiment, conductive adhesive can be acrylic tackifier or conductive epoxy resin.Metal forming adhesive tape for tool non-conductive adhesive stick, metal forming can have embossed surface (it allows the part of metal forming directly to electrically contact top surface and the basal surface of solar cell), and the wherein top surface of non-conductive adhesive stick contact solar cell and the zone of basal surface.In a preferred embodiment, in the zone of metal forming contact solar cell, at least 10% surface area of metal forming embossed surface and top and the bottom of solar cell directly electrically contact.More preferably in situation, at least 40% surface area and the surface of solar cell directly electrically contact.In a preferred embodiment, conducting element 60 is the zinc-plated Copper Foils of embossing with pressure sensitive acrylic adhesive.
The thickness of conducting element 60 should be enough thick in to satisfy the resistivity requirement, and also enough thin so that material can fold.In a preferred embodiment, the thickness of metal forming adhesive tape at 0.01mm to approximately between 0.15mm, more preferably 0.025 to approximately between 0.05mm.
Also imagined conducting element 60 and can be multi-disc (2 or more multi-disc), as long as still can realize the above results.The illustrative configuration of folding (or a plurality of folding) in element 60 is presented in Fig. 7 A-7F.They are used for illustration purpose, should not be taken as the restriction to all possible bending configuration.
Also having imagined conducting element 60 self can be not exclusively folding, but keeps certain angle α, as shown in Figure 8A and 8B.In Fig. 8 A, battery 20 is positioned on Different Plane, and in Fig. 8 B, battery is placed on curved surface.It is envisaged that, angle [alpha] can be up to 360 °, but under preferable case it approximately between 0 ° to 90 °, more preferably approximately between 0 ° to 45 °, most preferably approximately between 0 ° to 15 °.
In another aspect of this invention, imagined assembly 10 and can also comprise other conducting elements 60, it can bend or can not bend, and plays the effect that the chain with battery 20 is connected with one or more end bars 70, as shown in Figure 9.End bar 70 plays the effect of conduit for the electric energy of assembly 20.Imagined and to have passed through adhesive (conductivity or dielectric), welding, soft soldering or possible any other and produce and/or keep being connected between element 60 and end bar 70 in conjunction with the knot technology.
The first encapsulating material layer 40
It is envisaged that, photovoltaic cell component can also comprise the first optional encapsulating material layer 40, and it can carry out several functions.For example, this layer 40 can play the effect of bonding mechanism, thereby helps adjacent layer is kept together (for example battery 20, conducting element 60 and/or the second encapsulating material layer 50).It also allows the luminous energy of desired amount and type to see through to arrive photovoltaic cell 20 (for example the photolytic activity part 24).The first encapsulating material layer 40 also can play the effect of the geometry scrambling that compensates adjacent layer or the scrambling (for example varied in thickness) that shows by those layers.It also can play and allow to move and to bend the deflection that causes and the effect of the movement between layer by environmental factor (such as variations in temperature, humidity etc.) and physics.In preferred embodiments, the first encapsulating material layer 40 can be made of adhesive foil or net basically, but is preferably thermoplastic for example EVA (ethane-acetic acid ethyenyl ester), TPO or similar material.It is envisaged that, this layer 40 can be made of simple layer, perhaps can be made of multilayer (such as first, second, third, fourth, layer 5 etc.).The preferred thickness of this layer 40 can be about 0.1mm to 1.0mm, more preferably from about 0.2mm to 0.8mm, 0.25mm to 0.5mm most preferably from about.
It is envisaged that, " well " adhesion that obtains by encapsulating material layer and all surface sorptions to be contacted is important for the integrality of keeping the assembly of sealing.As general criterion, for the measured adhesion of the absorption of glass should be higher than about 20N/15mm, more preferably higher than about 30N/15mm, and even more preferably higher than about 40N/15mm.Adhesion strength can be measured with 180 ° of distraction tests of the standard described in ASTM D903-98.
The second encapsulating material layer 50
In another example of encapsulating material layer, be placed in to the second optional encapsulating material layer 50 common connectivities photovoltaic cell 20 belows, although it can directly contact the first encapsulating material layer 40 in some cases.Imagine the second encapsulating material layer 50 and can play with the first encapsulating material layer and similarly act on, although it is not essential transmission of electromagnetic radiation or luminous energy.
Method
It is envisaged that, the method that photovoltaic cell 20 is assembled into assembly 10 is also creative.Imagination provides above-mentioned all parts, and comprises the steps for the manufacture of the assemble method of assembly 10.Solar cell can provide in batches or in heaps, and is provided to discharge point manually or automatically.Alternatively, solar cell 20 can provide with the form of the continuous volume that comprises a plurality of solar cells, and separates from volume be called as the step of cutting single (singulation) before being about to assembling in.The solar cell that is cut into single can be provided in the bin (bin) of classifying according to photovoltaic performance.The battery 20 that is provided in bin can by operating personnel's manually load individually, perhaps more preferably can use industrial robot sort out single battery and be placed in the test zone from bin in situation.Then can use picture system to instruct industrial robot photovoltaic cell 20 is accurately sorted out and be placed on the flat-top vacuum transport belt with correct orientation.In one embodiment, picture system comprises the camera of the picture that obtains the battery top surface, and will be sent to robot about the accurate directed information of battery, so that robot can sort out it and be placed on conveyer belt with pinpoint direction.
Place the first battery in the solar cell string so that the basal surface of conductive substrates 22 close solar cell 20 leading edges 32 contacts the first end bar.For example conductive epoxy resin or scolder are connected to the first solar cell with the first end bar to use the conductive adhesive component.Alternatively, can the first solar cell be connected with the first end bar by conducting element 60, described conducting element can be provided for solar cell interconnect by the following stated mode.In order to make cell interconnect, that conducting element is folding at least one times around axle.It is envisaged that, conducting element can provide with conitnuous forms, and for example on roller, and folding operation can carry out with a series of mechanical guidance devices and the pressure roller of folding conducting element.Then can use mechanical cutter for example to mediate cutter folding conducting element is cut into suitable length.Preferably folding conducting element is provided as the metal forming adhesive tape.Yet, if conducting element 60 is provided as metal forming, so before placing conducting element 60, must with conductive adhesive for example conductive epoxy resin be applied on the top surface of solar cell 20 on the bus on current collecting 28.
Then folding conducting element is applied to the top of the first solar cell 20 near trailing edge 34 places and accurate location, so that contact with the top surface of solar cell on the bus of conducting element part of current collecting 28 or " grid " on as solar cell surface, and be parallel to the trailing edge 34 of battery.Then the suitable length of vacuum transport belt transposition (index), and the second solar cell accurately is placed on vacuum transport belt so that the contact of the basal surface of the conductive substrates 22 of the second solar cell has been applied to the folding conducting element 60 on the first solar cell.The trailing edge 34 of imagining the leading edge 32 of the second solar cell and the first solar cell is overlapping.Repeat to apply the process of conducting element and battery until complete desired string length.After last battery in placing string, the second end bar can be applied on the top surface of last battery so that the end bar in the end contacts with the bus of current collecting 28 near the trailing edge 34 of a battery.For example conductive epoxy resin or scolder are fixed in the first end bar on the first solar cell to use the conductive adhesive component.In the situation of conductive epoxy resin, conductive epoxy resin should be applied on the bus of last battery before the second end bar is provided.Alternatively, the first solar cell can be connected with the first end bar by conducting element 60, and described conducting element can be provided for the interconnection of solar cell in the above described manner.
After the interconnecting assembly that is connected with the end bar at the opposite ends place is completed, can be with the solar cell tandem arrangement between the first encapsulating material layer 40 and the second encapsulating material layer 50.The product that will have the first encapsulating material layer 40, solar cell 20, a plurality of conducting element 60, end bar and the second encapsulating material layer 50 is lamination in vacuum laminator for example, and completes thus assembling.
Except as otherwise noted, otherwise size and the geometry of the various structures of describing in this article are not intended to limit the present invention, and other size or geometry are also possible.A plurality of structure members can be provided by single overall structure.Alternatively, single overall structure can be divided into independent a plurality of parts.In addition, although feature of the present invention may be described in the situation of an exemplary only, such feature can be used for one or more other Feature Combinations of other embodiments any given application.It should further be appreciated that from foregoing, the manufacturing of unique texture herein and operation thereof have also consisted of method of the present invention.
The preferred embodiments of the invention are disclosed.Yet those of ordinary skill in the art will recognize, some modification will be in teachings of the present invention.Therefore, following claim be should study and true scope of the present invention and content determined.
Any numerical value of enumerating in above-mentioned application comprises from smaller value to higher value all values with the incremental increase of a unit, as long as be separated by at least 2 units between any smaller value and any higher value.For example, if the value of mentioning the amount of certain component or process variables (such as temperature, pressure, time etc.) for for example 1 to 90, preferred 20 to 80, more preferably 30 to 70, the value sought for such as 15 to 85,22 to 68,43 to 51,30 to 32 etc. of meaning also is explicitly recited in this specification.For less than 1 value, suitably situation next unit is considered to 0.0001,0.001,0.01 or 0.1.These are only the examples of the numerical value of concrete intention indication, and all possible combination of the numerical value between minimum and peak all should be considered in a similar fashion statement clearly in this manual.
Except as otherwise noted, otherwise all scopes comprise all numerals between two end points and end points.Combine with scope " approximately " or " being similar to " of using be applicable to two end values of described scope.Therefore, " approximately 20 to 30 " is intended to cover " approximately 20 to approximately 30 ", and comprises the end points that indicates at least.
The disclosure of all articles and list of references (comprising patent application and open) is incorporated into by reference for all purposes.
Be used for to describe combination term " basically by ... consist of " should comprise the key element, composition, parts or the step that indicate, and other key elements of this class, composition, parts or the step of the fundamental sum novel feature that substantial effect should combination.
Term that use to describe in this article the combination of key element, composition, parts or step " comprises " or " comprising " also contains the embodiment that basically is made of described key element, composition, parts or step.
A plurality of key elements, composition, parts or step can be provided by single integrated key element, composition, parts or step.Alternatively, single integrated key element, composition, parts or step can be divided into independently a plurality of key elements, composition, parts or step.Be used for describing key element, composition, parts or step that " one (a) " or " one " of key element, composition, parts or step is not intended to get rid of other.Herein all of the element that belongs to certain family or metal are referred to and refer to the Press by CRC, Inc., 1989 publish and have the periodic table of elements of copyright.It is as using the IUPAC system to carry out family's numbering and one or more families of reflection in this periodic table of elements that one or more families any referred to.
The element number list
Photovoltaic cell component 10
Photovoltaic cell 20
Conductive basal layer 22
Photoactive layer 24
Basal surface 25
Top surface 26
Conductive trace 27
Current collecting 28
Bus 29
Non-conductive layer part 30
Conducting element 60
The outer surface 66 of conducting element 60
End bar 70
The length L of conducting element C
The width W of conducting element C
Lap C A
Back contact 122
CuInGaSe (S) absorbed layer 124
Resilient coating 126
Window layer 128
Transparency conducting layer 130

Claims (15)

1. photovoltaic cell component, it comprises:
A plurality of photovoltaic cells, described photovoltaic cell comprises:
Photolytic activity part with top surface;
Top current collecting on described top surface; And
Described photolytic activity part with described top surface opposite sides on opposite conductive base
Bottom;
The first conducting element with first surface, wherein said the first conducting element bending is at least one times;
The opposite conductive basal layer of the described top current collecting of wherein said first surface and the first photovoltaic cell and/or described top surface and adjacent the second photovoltaic cell contacts; At least a portion of wherein said first surface keeps in touch by adhesive and described battery in addition.
2. the photovoltaic cell component of claim 1, wherein said a plurality of photovoltaic cell also respectively comprises leading edge and trailing edge, wherein said conducting element and described the first photovoltaic cell contact at described trailing edge place, and the opposite conductive basal layer of described conducting element and described adjacent the second photovoltaic cell is in the place's contact of described leading edge, and the trailing edge of the leading edge of wherein said adjacent the second photovoltaic cell and described the first photovoltaic cell is overlapping in addition.
3. the photovoltaic cell component of aforementioned claim any one, wherein said top current collecting comprises a series of isolated electric conducting material traces, and it is compared with described top surface has lower sheet resistance.
4. the photovoltaic cell component of claim 3, wherein the top current collecting comprises at least one bus.
5. the photovoltaic cell component of claim 1-4 any one, at least a portion of the form peripheral edge portions of wherein said battery comprises the non-conductive layer part.
6. the photovoltaic cell component of claim 5, wherein said non-conductive layer partly comprises by the liquid dielectric of UV hardening with radiation or non-conductive band.
7. the photovoltaic cell component of aforementioned claim any one, wherein said conducting element is the conductivity adhesive tape.
8. the photovoltaic cell component of aforementioned claim any one, wherein said conducting element is the foil belt with embossed surface, and at least 10% surface area of wherein said embossed surface directly contacts with described battery.
9. the photovoltaic cell component of aforementioned claim any one, wherein said adhesive is conductive adhesive.
10. the photovoltaic cell component of claim 1-8 any one, wherein said adhesive is non-conductive adhesive.
11. the photovoltaic module of aforementioned claim any one, wherein said at least one angle α that is bent to form is between 0 ° to 90 °.
12. the photovoltaic module of aforementioned claim any one, the wherein said conducting element overlapping length on described conductive basal layer is 2.0mm at least.
13. the photovoltaic module of aforementioned claim any one, the area at least about 10% of the lap of wherein said conducting element and described bus is overlapping.
14. the photovoltaic module of aforementioned claim any one, wherein said conducting element comprise a plurality of folding.
15. a method of making photovoltaic module, described method comprises the steps:
(a) provide at least two solar cells, described solar cell comprises photolytic activity part, top current collecting and the bottom conductive substrate with top surface, and wherein said battery comprises leading edge and trailing edge in addition;
(b) provide at least one conducting element, it respectively has first surface;
(c) provide at least one end bar;
(d) the first battery is placed to make with described a plurality of solar cells in the basal surface of the close described conductive substrates of the described leading edge of the first battery contact the first end bar;
(e) use conductive component that the first end bar is connected with described the first battery,
(f) the first conducting element is folding at least one times around axle;
(g) described folding conducting element be applied to described the first battery near the top of described trailing edge and accurately place so that top surface and/or the described top current collecting of the described solar cell of described conducting element contact; And
(h) the second battery is placed on the described folding conducting element that is applied on described the first solar cell, so that the described folding conducting element of the basal surface of the conductive substrates of described the second solar cell contact, thereby produce the string with the first battery and end cell
(i) randomly that other conducting element is folding at least one times around axle, described other folding conducting element is applied to described end cell near the top of described trailing edge and accurately places so that top surface and/or the described top current collecting of the described solar cell of described conducting element contact; And other battery is placed on the described folding conducting element that is applied on described end solar cell, so that the described folding conducting element of the basal surface of the conductive substrates of described other solar cell contact has the string of the first battery and at least one intermediate cell and end cell with formation, wherein previous end cell becomes intermediate cell
(j) repeating step (i) randomly,
(k) place the second end bar so that its top surface with last end solar cell contacts on bus, described bus is the part at the current collecting edge of described end solar cell;
(l) use conductive component that described the second end bar is connected with described last battery.
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